Magnetic detection apparatus and method of manufacturing the same

ABSTRACT

A magnetic detection apparatus can be improved in its product yield. The magnetic detection apparatus includes a resin compact having a the magnet arranged in opposition to an object to be detected for generating a magnetic field, an IC chip with a magnetic detection part built therein for detecting a change in the magnetic field in accordance with movement of the object to be detected, and an IC package in which a lead frame having the IC chip installed thereon is sealed with a resin. A method for manufacturing such a magnetic detection apparatus includes a signal adjustment step for adjusting a signal generated from the magnetic detection part in a state in which the magnetic field is applied to the magnetic detection part to correct a deviation of the signal of the magnetic detection part generated in accordance with a relative displacement between the magnetic detection part and the magnet.

CROSS REFERENCE

This is a divisional of application Ser. No. 10/704,672 filed Nov. 12,2003, which claims priority to Japanese Application 2003-280313 filedJul. 25, 2003. The entire disclosures of the prior applications isconsidered part of the disclosure of the accompanying continuationapplication and is hereby incorporated by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a method of manufacturing a magneticdetection apparatus capable of detecting the rotation angle of agear-wheel shaped magnetic rotor for instance. and it also relates to amagnetic detection apparatus obtained by such a method of manufacture.

2. Description of the Related Art

There has hitherto been known a magnetic detection apparatus including amagnet and an IC chip, which is arranged in the neighborhood of thismagnet and has a magnetoresistive element incorporated therein, fordetecting the rotation of a toothed magnetic rotor from a change in themagnetic field which is applied to a magnetic sensing element and ischanging in accordance with the rotation of the toothed magnetic rotorarranged in the proximity of the magnetic detection apparatus (forinstance, see a first patent document: Japanese patent No. 3235553).

In such a known magnetic detection apparatus, when a positionaldisplacement takes place between the magnet and the magnetoresistiveelement incorporated into IC chip in the manufacturing processes of theapparatus, such a displacement results in a variation in a bias magneticfield. In this case, if the variation is large, there will arise aproblem that the output of the magnetoresistive element does not cross acomparison level or threshold, resulting in a defective product whichfails to generate any pulse output.

SUMMARY OF THE INVENTION

Accordingly, the present invention is intended to obviate theabove-mentioned problem, and has its object to provide a magneticdetection apparatus and a method of manufacturing such a magneticdetection apparatus with improved product yield.

Bearing the above object in mind, the present invention resides in amethod of manufacturing a magnetic detection apparatus which includes: aresin compact having a the magnet arranged in opposition to an object tobe detected for generating a magnetic field; an IC chip with a magneticdetection part built therein for detecting a change in the magneticfield in accordance with a movement of the object to be detected; and anIC package in which a lead frame having the IC chip installed thereon issealed with a resin. The method includes a signal adjustment step foradjusting a signal which is generated from the magnetic detection partin a state in which the magnetic field is applied to the magneticdetection part so as to correct a deviation of the signal of themagnetic detection part generated in accordance with a relativedisplacement between the magnetic detection part and the magnet.

In the above-mentioned method of manufacturing a magnetic detectionapparatus according to the present invention, in order to correct adeviation of the signal output from the magnetic detection partgenerated in accordance with a relative displacement of the magneticdetection part and the magnet, provision is made for the signaladjustment process of adjusting the signal generated by the magneticdetection part with a magnetic field being applied to the magneticdetection part. As a result, it is possible to obtain the magneticdetection apparatus which is improved in its product yield.

The above and other objects, features and advantages of the presentinvention will become more readily apparent to those skilled in the artfrom the following detailed description of a preferred embodiment of thepresent invention taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross sectional side view of a magnetic detection apparatusaccording to a first embodiment of the present invention.

FIG. 2 is a partially exploded perspective view of an IC package and aresin compact of FIG. 1.

FIG. 3 is a plan view of the IC package of FIG. 1.

FIG. 4 is a cross sectional view of the neighborhood of a probingportion of FIG. 2.

FIG. 5 is an electric circuit diagram of the magnetic detectionapparatus according to the first embodiment of the present invention.

FIG. 6 is a cross sectional view showing another example of theneighborhood of the probing portion.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Now, a preferred embodiment of the present invention will be describedin detail while referring to the accompanying drawings.

Embodiment 1.

FIG. 1 shows a cross sectional side view of a magnetic detectionapparatus constructed in accordance with a first embodiment of thepresent invention.

The magnetic detection apparatus includes a resin mold or compact 2having a magnet 1 arranged in opposition to an object to be detected inthe form of a toothed magnetic rotor with concave and convex portions(not shown) for generating a magnetic field, an IC package 4 having anIC chip 3 built therein, into which a magnetic detection part in theform of magnetoresistive elements is incorporated for detecting a changein the magnetic field generated by the magnet 1 and changing inaccordance with the rotation of the magnetic rotor, and an exteriorresin 18 with which the IC package 4 and the resin compact 2 areresin-sealed.

The IC package 4 includes chip parts 5 such as resistances, capacitors,etc., which form a protection circuit against external noise, a firstnon-magnetic lead frame 6 with which the chip parts 5 and the IC chip 3are electrically connected by soldering, a gold wire 7 electricallyconnecting prescribed terminals to be described later with one another,and a first resin portion 8 with which the IC chip 3, the chip parts 5and the first lead frame 6 are resin-sealed by insert molding.

A protruded press-fit portion 9 is formed on a lower surface of thefirst resin portion 8, and a pair of pins 10, which protrudes in thesame direction as the press-fit portion 9 does as shown in FIG. 2, arealso formed on the lower surface of the first resin portion 8.

A plurality of probing portions 16 are provided on adjustment terminalsof the first lead frame 6, as shown in FIG. 3 and FIG. 4, and aplurality of grooves 17, acting as an infiltration preventive part forpreventing a resin from infiltrating the probing portions 16, are formedto surround the probing portions 16, respectively.

The resin compact 2 includes a second lead frame 12 electricallyconnected by welding with the first lead frame 6 and having a connectorterminal 11 for outputting an output signal of the magnetoresistiveelements to an external member, and a second resin portion 13 with whichthe second lead frame 12 is resin-sealed by insert molding. In addition,on an upper surface of the second resin portion 13, there is formed aconcave portion 14 into which the press-fit portion 9 is press-fitted.Also, on the upper surface of the second resin portion 13, there areformed a pair of holes 15 into which the pins 10 are fitted, as shown inFIG. 2. The pins 10 and the press-fit portion 9 of the IC package 4 aswell as the holes 15 and the concave portion 14 of the resin compact 2together constitute a positioning and integrating part which determinesthe relative position between the IC package 4 and the resin compact 2and combines them into an integral unit.

In the magnetic detection apparatus as constructed above, the concaveportions and convex portions of the magnetic rotating member arranged ata location near the apparatus alternately come into the proximity of themagnetoresistive elements built into the IC chip 3 in accordance withthe rotation of the magnetic rotating member, so that the magnetic fieldfrom the magnet 1 applied to the magnetoresistive elements is changed.Such a change in the magnetic field is detected by the magnetoresistiveelements as a change in its resistance. The change in the resistancegenerated in the magnetoresistive elements is sent to a computer unit(not shown) through the connector terminal 11, whereby the number ofrevolutions per minute of the magnetic rotating member is detected bythe computer unit.

Now, a method of manufacturing the magnetic detection apparatus asconstructed above will be explained below.

First of all, the characteristic variation of the magnetoresistiveelements is first adjusted. Such an adjustment has been done even in theabove-mentioned known magnetic detection apparatus, and here is alsocarried out with respect to the IC chip 3 into which themagnetoresistive elements are built. The number of probe portions neededfor signal adjustment in the post processing is reduced by thisadjustment process.

Here, the adjustment of the characteristic variation of themagnetoresistive elements will be explained in detail.

FIG. 5 is a circuit diagram of the magnetic detection apparatus. Abridge circuit 22 comprising a first magnetoresistive element 20 and asecond magnetoresistive element 21 is connected with a differentialamplifier circuit 23. The differential amplification circuit 23 performsprescribed amplification of the voltage generated in a midpoint 24 inthe bridge circuit 22 and generates it as an output. The output of thedifferential amplifier circuit 23 is converted into a two-level signalin a comparison circuit 25, which is finally output as a pulse wave froman output terminal 30 through an output circuit 26. At this time, ifthere is a difference between the resistance values of the firstmagnetoresistive element 20 and the second magnetoresistive element 21,this difference is amplified, resulting in a situation where the outputof the differential amplifier circuit 23 does not cross a comparisonlevel or threshold of the comparison circuit 25.

In order to avoid such a situation, a reference voltage of thedifferential amplifier circuit 23 is adjusted. Concretely, by adjustingthe resistance value of a resistance adjustment portion 27 of thedifferential amplifier circuit 23 that determines the reference voltagethereof, the characteristic variations of the first magnetoresistiveelement 20 and the second magnetoresistive element 21 are adjusted.

After the adjustment of the characteristic variations of the firstmagnetoresistive element 20 and the second magnetoresistive element 21has been completed, the IC chip 3 and the chip parts 5 are installed onthe first non-magnetic lead frame 6, and the prescribed terminalsthereof are mutually connected with one another by the gold wire 7,whereafter they are resin-sealed by the first resin portion 8 to producethe IC package 4. The purpose of using the first lead frame 6 of anon-magnetic material is to prevent the scattering of magnetic field.

Then, the IC package 4 thus produced is assembled to the resin compact2. At this time, the press-fit portion 9 and the pins 10 of the ICpackage 4 are fitted into the concave portion 14 and the holes 15 of theresin compact 2, respectively, whereby the IC package 4 and the resincompact 2 are integrally coupled with each other so as not to generateplay or rattle therebetween. In this connection, it is to be noted thatwith respect to the positioning and integration of the IC package 4 andthe resin compact 2, the present invention is not particularly limitedto the above arrangement and construction as long as they are properlypositioned and integrated in a reliable manner.

Subsequently, in order to correct a deviation of the output signalgenerated from the output terminal 30 in accordance with a relativedisplacement between the magnetoresistive elements of the IC package 4and the magnet 1 of the resin compact 2, an adjustment is carried outagain.

Specifically, the resistance value of a resistance adjustment portion 28that determines the comparison level of the comparison circuit 25 isadjusted for this purpose. In this regard, both the resistanceadjustment portion of this comparison circuit 25 and the resistanceadjustment portion 27 of the aforementioned differential amplifiercircuit 23 are resistance adjustment portions in the IC chip 3. Thus, byperforming the resistance adjustment of these resistance adjustmentportions, any additional resistance adjustment part such as, forinstance, a trimmable resistor or the like is not needed, therebyensuring the reduction in size of the apparatus.

Here, the Zener-zapping technique is employed as an adjustment means forthe resistance adjustment portion 28. The Zener-zapping technique is atechnique of short-circuiting a resistor by causing electric current toflow through a transistor arranged in parallel to the resistor throughthe probing portions 16. That is, the resistance value of the resistorexists in the absence of such adjustment, but it becomes possible tomake the resistance value to zero by performing the above adjustment.

In the Zener-zapping technique, adjustment can be made by causing theelectric current to flow between the probing portions 16, so there is nonecessity to expose the resistance adjustment portion 28, and hence itis possible to adjust the resistance value of the resistance adjustmentportion 28 while the IC chip 3 is sealed with a resin material.

In general, the resin material for sealing the IC chip 3 is an epoxyresin, which has very high flowability, and hence portions wanted to beexposed are sometimes coated with such an resin, depending on thethickness variation and molding conditions of the first lead frame 6.Thus, if the probing portions 16 are coated with the resin, it becomes,of course, impossible to cause electric current to flow through theprobing portions 16, so the resistance adjustment in the IC chip 3 cannot be made.

In this case, however, the grooves 17, being formed around the probingportions 16, respectively, serve to prevent the resin from coming intothe probing portions 16, whereby exposure of the probing portions 16 isensured, thus making it possible to perform stable resistanceadjustment.

In methods such as, for instance, a laser cutting method, etc., otherthan the Zener-zapping technique, it is necessary to expose the surfaceof the IC chip 3 to the outside so as to directly cut the wiring of theIC chip 3. In addition, in this case, it is also necessary to payattention to short-circuiting due to dust, corrosion due to humidity orthe like.

Thereafter, an end portion of the first lead frame 6 of the IC package 4is connected by welding with an end portion of the second lead frame 12of the resin compact.

Finally, the IC package 4 and the resin compact 2 thus integrated aresealed with a resin by means of insert molding with the connectorterminal 11 being exposed, whereby a magnetic detection apparatus withits outer surface covered with the exterior resin 18 is produced.

Although in the above-mentioned embodiment, reference has been made tothe case in which the grooves 17 are provided as an infiltrationpreventive part, a wall 19 may instead be formed to surround each of theprobing portions 16, as shown in FIG. 6. Such a wall 19 can be formed byperforming plating, applying a resin, pasting a seal or the like.

In addition, although in the above embodiment, the magnetoresistiveelements 20, 21 have been used as the magnetic detection part, themagnetic detection part is, of course, not limited to suchmagnetoresistive elements but may comprise a hall element capable ofconverting a change in the magnetic field into a corresponding voltage.

While the invention has been described in terms of a preferredembodiment, those skilled in the art will recognize that the inventioncan be practiced with modifications within the spirit and scope of theappended claims.

1. A method of manufacturing a magnetic detection apparatus whichincludes: a resin compact having a the magnet arranged in opposition toan object to be detected for generating a magnetic field; an IC chipwith a magnetic detection part built therein for detecting a change insaid magnetic field in accordance with a movement of said object to bedetected; and an IC package in which a lead frame having said IC chipinstalled thereon is sealed with a resin; said method comprising asignal adjustment step for adjusting a signal which is generated fromsaid magnetic detection part in a state in which said magnetic field isapplied to said magnetic detection part so as to correct a deviation ofthe signal of said magnetic detection part generated in accordance witha relative displacement between said magnetic detection part and saidmagnet.
 2. The method of manufacturing a magnetic detection apparatus asset forth in claim 1, further comprising an integration step forcombining said IC package and said resin compact with each other to forman integral unit, said integration step being followed by said signaladjustment step.
 3. The method for manufacturing a magnetic detectionapparatus as set forth in claim 1, wherein in said signal adjustmentstep, the resistance values of resistance adjustment portions built intosaid IC chip are adjusted.
 4. The method of manufacturing a magneticdetection apparatus as set forth in claim 3, wherein the adjustment ofsaid resistance adjustment portions is carried out by the Zener-zappingtechnique.